FWIW there does not seem to be an elegant solution to steering rack leaks at the wires that enter the steering box. These leaks can fool you into thinking the pump is leaking because the pump is directly over the wire bundle. The pump vs. wire bundle leak is easy to diagnose by putting a clean paper towel under the pump. Wet towel is the pump. Dry towel is the wire bundle.

Even Turn1 has no solution for this leak. They have a disclaimer on their website about it.

Here is the solution I have used 3 times under race conditions and it has worked 3 times. I blast out the wire bundle where it exits the rack with brake cleaner. I blast compressed air in there to dry it. I repeat this process. I inject 5min clear epoxy into the bundle where the wires exit as deep as I can with a needle without damage to the wires. After the 5mins I inject more 5min epoxy around the wire bundle as it exits and on to the body of the clean metal of the steering box. The key is getting area clean so epoxy can stick and seal before the oil oozes out hence 5min epoxy.

No different racks all c5 vettes. My problem with rtv was it did not dry fast enough. But I guess rtv would be good for a slow leak. The key is the glue drying before the surface gets oiled again from when you clean it.

Had the same problem years ago with my '01 coupe; pulled the rack out to work on it, used JB Weld and High Temp Silicone to fix (after a good cleaning). Sold the car two years later and fix was still holding. Good luck

What causes this? Heat, rpm, both... I haven't tracked my car yet but I had to replace the hi psi hose on my c6 and while I had it apart I added a 4 pass trans cooler in front of the radiator, added a magnafine filter on the return and flush and filled with redline fluid.

I just had this problem on my C5 and a buddy has it on his C6. Mine was a pretty slow leak. His was a little more severe. My friend Joel at Corvette Sports said he has seen it on a few cars and there is no real fix. He thinks some could be cause more for cars that get tracked from running on the rumbles at the corners. He said even if you put a whole new rack in it's a crap shoot that it wont happen to it too. He suggested I try Lucas Power Steering Stop Leak. I totally brake cleaned the area, then I emptied the reservoir and filled it with the Lucas. Went out to and empty parking lot and did about twenty minutes of figure 8's cranking the wheel full left and full right. Came back and parked in the garage for a week. No leak. So I repeated the process again just for good measure. Still no leak as of today. I did this over month ago. Now I don't drive my car a whole lot on the street. It's more a track car but it does see some street time. My C6 buddy said his has slowed down considerably. Has not totally stop it but way better than before. I may try to add the RTV or epoxy when it warms up around here but for now it seems to have stopped it.
Just my .02
Tim

Bumping this back up, I'm dealing with a leak at the wires on a recently installed rebuilt rack from Corvette Central (Lonestar). I've added the Lucas PS Stop Leak, now looking to try to seal the area around the wires.

Question for the OP: Is this the mixing tip you used? And you were able to get in there without pulling anything apart?

Yes those are the tips I used that happen to fit the epoxy tube. Anything will work. It is just hard to reach in there if you don't take things apart. I was lazy. Even a new rebuild rack can leak there. If I replace a rack I always epoxy the wires before install because now I can reach them. There are not new GM racks only rebuilds. in fact there are no rebuilds without exchanges too. I think Zip has a big core charge like $400 bucks!

No different racks all c5 vettes. My problem with rtv was it did not dry fast enough. But I guess rtv would be good for a slow leak. The key is the glue drying before the surface gets oiled again from when you clean it.

Fatbillybob - did you have any issues getting core refunds with racks you epoxied?

I have only sent in 1 that I epoxied. No one cared or noticed and I did not even think to volunteer. If I was receiving a rebuilt rack the 1st thing I would do is clean and epoxy the wires bundle while I got clean good access on the bench. It is a really difficult to clean the area and epoxy in situ but it can be done. I have done it.